Toyota Figured Out How To Build A Roll Cage In Just Three Days

Toyota has introduced Sequence Freezing Arc-welding (SFA), a groundbreaking technology designed to improve sustainability in motorsports while reducing race car production times.

Eventually, the technology should transfer to Toyota's mainstream production lines, but for now, the company is refining the art while building race cars. This innovative welding process was used to construct the roll cage for ROOKIE Racing's GR Yaris competing in Japan's Super Taikyu ST-Q class. The GR Yaris with an SFA-assembled roll cage has already competed in multiple races,

Development of SFA began in August 2023 when Toyota's Chairman, Akio Toyoda, identified the inefficiency of manual roll cage assembly during a visit to the Toyota Gazoo Racing facility in Finland. I don't know if you've ever seen a cage get welded into a car or waited for one to come back from roll cage installation—but it takes the better part of a month due to the intricate placement of the pipes, along with the deft touch of master welders.

Toyota says SFA revolutionizes this process by using robotics to replicate the precision of seasoned welders. Unlike conventional welding, which can cause distortion from excessive heat, SFA applies a slower, more controlled welding method. The slower speed eliminates distortion and allows for more complex and precise joint designs. Early estimates claim SFA reduces the weight of the welded components by approximately 25% and increases joint strength by 10 to 25%. For what it's worth, the welds also look incredible.

By combining SFA with a modular sub-assembly process, Toyota has slashed the production time for roll cages in body-in-white cars from weeks to just three days. The process involves creating roll cage modules separately before integrating and welding them into the vehicle body. This method not only accelerates production but also enhances the structural rigidity of the car.

In fact, Toyota says it was able to increase torsional rigidity by such an amount that drivers complained the car was too stiff. Of course, this is where damper and tire packages come to play, but Toyota has made an important discovery about how to tune chassis stiffness from the welded cage frame. Similar to KTM's Trellis frame used in MotoGP.

Toyota emphasized it will not replace human welders but rather free up their time for higher-skilled tasks, such as accommodating the unique requirements of top-tier rally drivers. More importantly, the technology aims to reduce costs and lead times, making motorsports more accessible for entry-level participants.

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